Carcass cabinet system and method for antimicrobial treatment of animal carcasses

ABSTRACT

An apparatus and method for applying an antimicrobial agent to whole or split animal carcasses include a closed or essentially closed chamber for limiting the escape of antimicrobial agent to the environment during antimicrobial treatment of the carcass. In one embodiment, a series of carcass cabinet panels moves in line with the passing animal carcass and forms an enclosure around the carcass by means of panels closing ahead of and behind the carcass. In another embodiment, the direction and spray pattern of positively charged aerosolized antimicrobial particles in a carcass cabinet is controlled by attracting the particles to preselected negatively charged regions within the carcass cabinet.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional PatentApplication 62/214,729, filed 4 Sep. 2015, the entire disclosure ofwhich is incorporated herein by reference.

FIELD OF THE INVENTION

This disclosure relates to apparatuses, methods, and systems forapplying an antimicrobial treatment agent to an animal carcass, and inparticular to carcass cabinets therefor.

DESCRIPTION OF THE RELATED ART

Currently, the most commonly used method for antimicrobial treatment ofanimal carcasses is hot water pasteurization. Hot water pasteurizationis a “flood” technology, relying on a large volume of water to ensurethat each carcass is fully covered or surrounded and exposed to heatacross its entire surface to reduce the levels of pathogens. One commontype of pasteurization “cabinet” known in the art is a one-piececabinet, comprising a portion that encloses one or more carcasses tohold steam. The one-piece cabinet moves forward and back, in a straightline, to enclose the carcass.

One-piece cabinets suffer from a number of drawbacks. The number ofintervention technologies and practices that can be used in conjunctionwith a one-piece cabinet is strictly limited. One-piece cabinets canalso be dangerous to workers in the immediate proximity of the cabinet.Furthermore, it can be difficult to assess and ensure complete coverageof the carcass with an intervention or treatment agent.

There is thus a long-felt need for devices, systems, and methods forantimicrobial treatment of animal carcasses that allows a wider range ofintervention technologies and practices while safeguarding workerwelfare. It is advantageous for such devices, systems, and methods toreliably ensure that the entire surface of the carcass is covered orsurrounded by an intervention or treatment agent.

BRIEF SUMMARY OF THE INVENTION

The invention provides a retractable carcass cabinet, comprising a topenclosure, comprising a leading top panel, a center top panel, and atrailing top panel; and a bottom enclosure, comprising a leading bottompanel, a center bottom panel, and a trailing bottom panel, wherein thetop and bottom enclosures are configured to move between a retractedposition and a sealing position, and wherein, when the top and bottomenclosures are in a sealing position, the top and bottom enclosurestogether form a substantially airtight closed chamber.

In some embodiments, the retractable carcass cabinet may furthercomprise an electrostatic nozzle, disposed on an underside of the centertop panel and adapted to provide an electrostatic spray of anantimicrobial agent into the substantially airtight closed chamber; anevacuation port, disposed on the bottom enclosure and adapted toevacuate the substantially airtight closed chamber; and a relief airport, disposed on the bottom enclosure and adapted to inject air intothe substantially airtight closed chamber.

In some embodiments, a carcass hook may be disposed through a sealedopening in the top enclosure and extend below the top enclosure. Thecarcass hook may be attached to a carcass chain above the top enclosure.The center top panel may be attached to a top enclosure drive chain atan upper contact point on an overside of the center top panel, and thecenter bottom panel may be attached to a bottom enclosure drive chain ata lower contact point on an underside of the center bottom panel.

The invention also provides a system for antimicrobial treatment of ananimal carcass, comprising a retractable carcass cabinet, a carcasschain, a top enclosure drive chain, and a bottom enclosure drive chain.The retractable carcass cabinet comprises a top enclosure, comprising aleading top panel, a center top panel, and a trailing top panel; abottom enclosure, comprising a leading bottom panel, a center bottompanel, and a trailing bottom panel; an electrostatic nozzle, disposed onan underside of the center top panel; an evacuation port, disposed onthe bottom enclosure; and a relief air port, disposed on the bottomenclosure, wherein the top and bottom enclosures are configured to movebetween a retracted position and a sealing position. The carcass chaindrives a carcass hook, the carcass hook suspending the animal carcassbetween the top enclosure and the bottom enclosure. The top enclosuredrive chain is attached to the center top panel at an upper contactpoint on an overside of the center top panel. The bottom enclosure drivechain is attached to the center bottom panel at a lower contact point onan underside of the center bottom panel. The top enclosure drive chainand the bottom enclosure drive chain move the top enclosure and thebottom enclosure, respectively, to align the top and bottom enclosureswith the animal carcass. When the top and bottom enclosures are in asealing position, the top and bottom enclosures together form asubstantially airtight closed chamber surrounding the animal carcass.

In some embodiments, the animal carcass may be a whole animal carcass.The whole animal carcass may, by way of non-limiting example, be acattle carcass, a pig carcass, a sheep carcass, a sheep carcass, achicken carcass, a turkey carcass, or a carcass of a bird other than achicken or a turkey.

In some embodiments, the animal carcass may be a portion of a carcass ofan animal that has been cut, split, or otherwise separated from aremainder of the carcass. The animal may, by way of non-limitingexample, be cattle, a pig, a sheep, a chicken, a turkey, or a bird otherthan a chicken or a turkey.

The invention further provides a method for continuous antimicrobialtreatment of animal carcasses. In the first step of the method, aretractable carcass cabinet is provided at a process starting point, theretractable carcass cabinet comprising a top enclosure, a bottomenclosure, an electrostatic nozzle, an evacuation port, and a relief airport, wherein the top and bottom enclosures are configured to movebetween a retracted position and a sealing position. The method furthercomprises suspending an animal carcass between the top enclosure and thebottom enclosure by a carcass hook; driving the carcass hook along acarcass chain; driving the top enclosure along a top enclosure drivechain and the bottom enclosure along a bottom enclosure drive chain, sothat the top and bottom enclosures are aligned with the animal carcass;moving the top and bottom enclosures from the retracted position to thesealing position; electrostatically spraying an antimicrobial agent intothe substantially airtight closed chamber; evacuating the substantiallyairtight closed chamber; providing relief air into the substantiallyairtight closed chamber; moving the top and bottom enclosures from thesealing position to the retracted position; and driving the topenclosure along the top enclosure drive chain and the bottom enclosurealong the bottom enclosure drive chain to return the top and bottomenclosures to the process starting point. The top enclosure comprises aleading top panel, a center top panel, and a trailing top panel. Thebottom enclosure comprises a leading bottom panel, a center bottompanel, and a trailing bottom panel. The electrostatic nozzle is disposedon an underside of the center top panel. The evacuation port is disposedon the bottom enclosure. The relief air port is disposed on the topenclosure.

In some embodiments, the animal carcass may be a whole animal carcass.The whole animal carcass may, by way of non-limiting example, be acattle carcass, a pig carcass, a sheep carcass, a sheep carcass, achicken carcass, a turkey carcass, or a carcass of a bird other than achicken or a turkey.

In some embodiments, the animal carcass may be a portion of a carcass ofan animal that has been cut, split, or otherwise separated from aremainder of the carcass. The animal may, by way of non-limitingexample, be cattle, a pig, a sheep, a chicken, a turkey, or a bird otherthan a chicken or a turkey.

The invention still further provides a system for antimicrobialtreatment of at least one animal carcass, comprising a plurality ofcarcass cabinet walls, defining an interior volume; a plurality ofelectrostatic nozzles, aerosolizing a liquid antimicrobial agent to formaerosolized antimicrobial particles, imparting a positive charge to theaerosolized antimicrobial particles, and spraying the aerosolizedantimicrobial particles into the interior volume; a carcass chain,carrying the at least one animal carcass and driving the at least oneanimal carcass through the interior volume such that at least a firstportion of the aerosolized antimicrobial particles adheres to a surfaceof the at least one animal carcass to form a substantially uniform layerof the antimicrobial agent; a plurality of negatively chargedelectromagnets, each negatively charged electromagnet imparting anegative charge to an evacuation region within the interior volume toattract at least a second portion of the aerosolized antimicrobialparticles into the evacuation region; and a plurality of evacuationcolumns, each evacuation column associated with at least one negativelycharged electromagnet and evacuating substantially all of theaerosolized antimicrobial particles within the evacuation region fromthe interior volume.

In some embodiments, the at least one animal carcass may comprise awhole animal carcass. The whole animal carcass may, by way ofnon-limiting example, be a cattle carcass, a pig carcass, a sheepcarcass, a sheep carcass, a chicken carcass, a turkey carcass, or acarcass of a bird other than a chicken or a turkey.

In some embodiments, the at least one animal carcass may comprise aportion of a carcass of an animal that has been cut, split, or otherwiseseparated from a remainder of the carcass. The animal may, by way ofnon-limiting example, be cattle, a pig, a sheep, a chicken, a turkey, ora bird other than a chicken or a turkey

In some embodiments, the carcass cabinet walls may comprise stainlesssteel.

In some embodiments, the aerosolized antimicrobial particles may have anaverage diameter of between about 20 microns and about 60 microns.

In some embodiments, an attractive force between the surface of the atleast one animal carcass and the layer of the antimicrobial agent may beequal to about 75 times the force of gravity.

The invention yet further provides a method for continuous antimicrobialtreatment of animal carcasses, comprising the steps of a) providing aplurality of carcass cabinet walls defining an interior volume; b)aerosolizing a liquid antimicrobial agent to form aerosolizedantimicrobial particles; c) imparting a positive charge to theaerosolized antimicrobial particles; d) spraying the aerosolizedantimicrobial particles into the interior volume; e) driving at leastone animal carcass through the interior volume such that at least afirst portion of the aerosolized antimicrobial particles adheres to asurface of the at least one animal carcass to form a substantiallyuniform layer of the antimicrobial agent; f) imparting a negative chargeto at least one evacuation region within the interior volume to attractat least a second portion of the aerosolized antimicrobial particlesinto the at least one evacuation region; and g) evacuating substantiallyall of the aerosolized antimicrobial particles within the evacuationregion from the interior volume.

In some embodiments, the at least one animal carcass may comprise awhole animal carcass. The whole animal carcass may, by way ofnon-limiting example, be a cattle carcass, a pig carcass, a sheepcarcass, a sheep carcass, a chicken carcass, a turkey carcass, or acarcass of a bird other than a chicken or a turkey.

In some embodiments, the at least one animal carcass may comprise aportion of a carcass of an animal that has been cut, split, or otherwiseseparated from a remainder of the carcass. The animal may, by way ofnon-limiting example, be cattle, a pig, a sheep, a chicken, a turkey, ora bird other than a chicken or a turkey.

In some embodiments, the carcass cabinet walls may comprise stainlesssteel.

In some embodiments, the aerosolized antimicrobial particles may have anaverage diameter of between about 20 microns and about 60 microns.

In some embodiments, an attractive force between the surface of the atleast one animal carcass and the layer of the antimicrobial agent may beequal to about 75 times the force of gravity.

These and other advantages will be apparent from the disclosurecontained herein.

For purposes of further disclosure and to comply with applicable writtendescription and enablement requirements, the following referencesgenerally relate to systems and methods for antimicrobial treatment ofanimal carcasses and for related systems and methods, and are herebyincorporated by reference in their entireties:

U.S. Pat. No. 4,852,216, entitled “Animal slaughtering chemicaltreatment and method,” issued 1 Aug. 1989 to Clayton et al. (“ClaytonI”). Clayton I describes a material and method for processing meat inproduction in which the meat, both carcass and head, which can proceedon different production lines, is rinsed and treated with acetic acidafter hide removal. The water and acid are maintained at a temperatureof between 80 and 150° F. The acid is in a water-based solution atconcentrations ranging from 0.25% to 2.00%. After evisceration for thecarcass and removal of waste from the head, the head and carcass arerinsed and treated with acetic acid again before being sent to coldstorage, from which they are released later for further processing. Thefirst rinsing step is commenced within one hour of the time the hide isremoved from the animal.

U.S. Pat. No. 4,862,557, entitled “Animal slaughtering chemicaltreatment and method,” issued 5 Sep. 1989 to Clayton et al. (“ClaytonII”). Clayton II describes a material and method for processing meat inproduction in which the meat, both carcass and head, which can proceedon different production lines, is rinsed and treated with acetic acidafter hide removal. The water and acid are maintained at a temperatureof between 80 and 150° F. The acid is in a water-based solution atconcentrations ranging from 0.25% to 2.00%. After evisceration for thecarcass and removal of waste from the head, the head and carcass arerinsed and treated with acetic acid again before being sent to coldstorage, from which they are released later for further processing. Thefirst rinsing step is commenced within one hour of the time the hide isremoved from the animal.

U.S. Pat. No. 5,374,433, entitled “Method for preserving food products,”issued 20 Dec. 1994 to Bowling et al. (“Bowling I”). Bowling I describesa method for preserving a food product, such as meat. The methodcomprises the steps of inoculating meat with an effective amount ofeuhygienic non-pathogenic, non-spoilage bacteria in order tocompetitively inhibit the growth of undesired pathogenic and spoilagebacteria. Preferably, either L. delbrueckii or Hafnia alvei bacteria areused to inoculate a meat product. Bacteria present on a meat product arefirst reduced to a number below about 5,000 bacteria per gram of meat,e.g. by dehairing an animal and then spraying the meat with an organicacid prior to inoculation with euhygienic bacteria. The meat product isthen vacuum packaged and stored in a refrigerated environment of about−1° C. to about 7° C. Meat products preserved in accordance with themethod of the invention can enjoy a refrigerated shelf life of up toabout 150 days without surface discoloration or the generation ofundesirable gaseous byproducts.

U.S. Pat. No. 5,576,035, entitled “Method for preserving food productsand food products made thereby,” issued 19 Nov. 1996 to Bowling et al.(“Bowling II”). Bowling II describes a method for preserving a foodproduct, such as meat. The method comprises the steps of inoculatingmeat with an effective amount of non-pathogenic, non-spoilage bacteriain order to competitively inhibit the growth of undesired pathogenic andspoilage bacteria. Preferably, either L. delbrueckii or Hafnia alveibacteria are used to inoculate a meat product. Bacteria present on ameat product are first reduced to a number below about 5,000 bacteriaper gram of meat, e.g. by dehairing an animal and then spraying the meatwith an organic acid prior to inoculation with bacteria. The meatproduct is then vacuum packaged and stored in a refrigerated environmentof about −1° C. to about 7° C. Meat products preserved in accordancewith the method of the invention can enjoy a refrigerated shelf life ofup to about 150 days without surface discoloration or the generation ofundesirable gaseous byproducts.

U.S. Pat. No. 5,853,320, entitled “Plucking apparatus for poultry,”issued 29 Dec. 1998 to Wathes et al. (“Wathes”). Wathes describes aplucking apparatus for plucking poultry carcasses on a shackle lineincluding a plurality of individual plucking units, one for each of anumber of carcasses to be plucked at any one time, and shielding meansincluded in or provided additionally to said plucking units, whereby theplucking heads of each said unit are shielded from the plucking heads ofthe neighboring units during plucking.

U.S. Pat. No. 5,869,113, entitled “Method for preserving food productsand food products made thereby,” issued 9 Feb. 1999 to Clayton et al.(“Clayton III”). Clayton III describes a method for preserving a foodproduct, such as meat, using the steps of inoculating meat with aneffective amount of euhygienic non-pathogenic, non-spoilage bacteria inorder to competitively inhibit the growth of undesired pathogenic andspoilage bacteria. Edible films that incorporate and/or cover euhygienicbacteria on the food product are used to ensure competitive inhibitionof undesired spoilage and pathogenic bacteria.

U.S. Pat. No. 5,980,375, entitled “Method and apparatus forantimicrobial treatment of animal carcasses,” issued 9 Nov. 1999 toAnderson et al. (“Anderson”). Anderson describes a two-stepantimicrobial treatment of animal carcasses prior to chill storage in acommercial slaughter operation. As a first step, the carcass is isolatedin a hot water pasteurization chamber and sprayed with recirculationwater at a temperature of at least 165° F. over its entire surface for atime sufficient to kill bacteria. Isolation is achieved with aircurtains across the entrance and exit openings, an exhaust system, and aliquid level control in the bottom of the chamber. Recirculation watercollected in the bottom of the chamber is filtered, combined with makeupwater, heated, and recirculated to the chamber. As a second step, thecarcass is isolated in an acid application chamber and sprayed with anorganic acid solution immediately prior to delivery to the chillstorage.

U.S. Pat. No. 6,039,984, entitled “Method for treating a food processingfacility,” issued 21 Mar. 2000 to Bowling et al. (“Bowling III”).Bowling III describes a method for preserving a food product, such asmeat, comprising the steps of inoculating meat with an effective amountof euhygienic non-pathogenic, non-spoilage bacteria in order tocompetitively inhibit the growth of undesired pathogenic and spoilagebacteria. Edible films that incorporate and/or cover euhygienic bacteriaon the food product are used to ensure competitive inhibition ofundesired spoilage and pathogenic bacteria.

U.S. Pat. No. 6,287,610, entitled “Method for increasing the tendernessof a meat product,” issued 11 Sep. 2001 to Bowling et al. (“BowlingIV”). Bowling IV describes a method for preserving a food product, suchas meat, including the steps of inoculating meat with an effectiveamount of euhygienic non-pathogenic, non-spoilage bacteria in order tocompetitively inhibit the growth of undesired pathogenic and spoilagebacteria. Edible films that incorporate and/or cover euhygienic bacteriaon the food product are used to ensure competitive inhibition ofundesired spoilage and pathogenic bacteria.

U.S. Pat. No. 6,569,474, entitled “System for preserving food products,”issued 27 May 2003 to Clayton et al. (“Clayton IV”). Clayton IVdescribes a method for preserving a food product, such as meat,including the steps of inoculating meat with an effective amount ofeuhygienic non-pathogenic, non-spoilage bacteria in order tocompetitively inhibit the growth of undesired pathogenic and spoilagebacteria. Edible films that incorporate and/or cover euhygienic bacteriaon the food product are used to ensure competitive inhibition ofundesired spoilage and pathogenic bacteria.

U.S. Patent Application Publication No. 2004/0052702, entitled “Foodproduct surface sterilization apparatus and method,” published 18 Mar.2004 to Shuman et al. (“Shuman”).

U.S. Pat. No. 6,742,720, entitled “Spray application system,” issued 1Jun. 2004 to Nolen (“Nolen I”).

U.S. Pat. No. 6,964,788, entitled “System for handling processed meatand poultry products,” issued 15 Nov. 2005 to Phebus et al. (“Phebus”).

U.S. Pat. No. 7,169,415, entitled “System for preserving fresh meatproducts,” issued 30 Jan. 2007 to Bowling et al. (“Bowling V”). BowlingV describes a method for preserving a food product, such as meat,comprising the steps of inoculating meat with an effective amount ofeuhygienic non-pathogenic, non-spoilage bacteria in order tocompetitively inhibit the growth of undesired pathogenic and spoilagebacteria. Edible films that incorporate and/or cover euhygienic bacteriaon the food product are used to ensure competitive inhibition ofundesired spoilage and pathogenic bacteria.

U.S. Patent Application Publication No. 2009/0081317, entitled“Microbiocidal control in the processing of meat-producing four-leggedanimals,” published 26 Mar. 2009 to McNaughton et al. (“McNaughton”).

U.S. Patent Application Publication No. 2009/0196967, entitled“Application system with recycle and related use of antimicrobialquaternary ammonium compound,” published 6 Aug. 2009 to Nolen et al.(“Nolen II”).

U.S. Patent Application Publication No. 2010/0093266, entitled “Machinefor scrubbing exterior of fowl and method of use thereof,” published 15Apr. 2010 to Chattin et al. (“Chattin”). Chattin describes a machine forscrubbing a fowl, wherein the machine comprises at least one pair ofopposing rotating brushes, wherein the fowl passes between said at leastone pair of opposing rotating brushes. The pair of opposing rotatingbrushes comprises a first rotating scrubber and a second rotatingscrubber having bristles extending therefrom. The fowl is suspended viaa shackle suspended from a track, wherein the height of the scrubbingmachine may be selectively varied via a threaded height adjuster. Thebristles of the machine are rotated, wherein the bristles contact theexterior of fowl traveling through the machine. Jets of water or othercleaning fluid spray inwardly to reach the fowl and the scrubbingbristles to rinse removed material from the fowl and bristles. Thebrushes are rotated through hubs attached to gears powered by a motor,wherein the gears may be selectively rotated in either direction.

U.S. Patent Application Publication No. 2011/0086146, entitled“Antimicrobial compositions for meat processing,” published 14 Apr. 2011to Knueven (“Knueven”). Knueven describes a method and composition forreducing microbes during a meat processing operation. The compositionincludes an acid blend that is a blend of (a) an organic acid selectedfrom the group consisting of lactic acid, acetic acid, and mixturesthereof, and (b) a second material selected from the group consisting ofalkali metal salts of inorganic acids, mineral acids, and mixturesthereof.

U.S. Patent Application Publication No. 2011/0136421, entitled “Cleaningapparatus and method,” published 9 Jun. 2011 to Brink et al. (“Brink”).Brink describes an apparatus and method for cleaning carcasses and adevice for mixing a cleaning substance that can be used in suchapplications. In some embodiments, the apparatus and method utilize amulti-phase cleaning substance spraying procedure in which the cleaningsubstance has desired levels of chlorine dioxide and is delivered to thecarcasses at desired flow rates, both of which can vary between phasesof the procedure and/or at different locations of the carcasses beingcleaned.

U.S. Patent Application Publication No. 2012/0225171, entitled “Methodfor controlling water content with decontamination in meats,” published6 Sep. 2012 to Garwood (“Garwood”). Garwood describes a method forproducing treated meat having a predetermined proportion of water in acontainer. The method includes treating meat that has lost water contentthrough evaporation with an agent capable of killing bacteria togetherwith an amount of water, wherein the amount of water corresponds to theamount of water that is lost through evaporation. The method providesmeat being treated with a bactericidal agent as well as providing meatwith the predetermined amount of water for packaging.

U.S. Patent Application Publication No. 2013/0231034, entitled “Methodand apparatus for processing livestock carcasses to destroymicroorganisms,” published 5 Sep. 2013 to O'Neil et al. (“O'Neil”).

U.S. Patent Application Publication No. 2014/0017364, entitled“Microbiocidal control in the processing of meat-producing four-leggedanimals,” published 16 Jan. 2014 to Liimatta (“Liimatta”). U.S. Pat. No.8,715,759, entitled “Method and apparatus for antimicrobial treatment ofmeat trimmings for subsequent grinding,” issued 6 May 2014 to Larson(“Larson”). Larson describes an antimicrobial intervention for theproduction of ground meats by treating the exterior of the meattrimmings with an antimicrobial agent before grinding. An apparatus forapplying an antibacterial agent to meat trimmings includes a closed oressentially closed chamber for limiting the escape of the antimicrobialagent to the environment during antimicrobial treatment of thetrimmings, an entrance system for introducing trimmings into the closedchamber while prevent or significantly limiting the antimicrobial agentfrom escaping into the environment, an application system for applyingan effective amount of the antimicrobial agent to exposed surfaces ofthe trimmings in the closed chamber, and an exit system for removing thetreated trimmings from the closed container while preventing orsignificantly limiting the escape of antimicrobial agent into theenvironment.

U.S. Patent Application Publication No. 2016/0088846, entitled“Antimicrobial compositions and methods of use thereof,” published 31Mar. 2016 to Lemons (“Lemons”).

U.S. Patent Application Publication No. 2016/0174585, entitled“Anti-microbial application equipment with controls,” published 23 Jun.2016 to Massey et al. (“Massey”).

As used herein, “at least one,” “one or more,” and “and/or” areopen-ended expressions that are both conjunctive and disjunctive inoperation. For example, each of the expressions “at least one of A, B,and C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “oneor more of A, B, or C,” and “A, B, and/or C” means A alone, B alone, Calone, A and B together, A and C together, B and C together, or A, B,and C together.

It is to be noted that the term “a” or “an” entity refers to one or moreof that entity. As such, the terms “a” (or “an”), “one or more,” and “atleast one” can be used interchangeably herein. It is also to be notedthat the terms “comprising,” “including,” and “having” can be usedinterchangeably.

The embodiments and configurations described herein are neither completenor exhaustive. As will be appreciated, other embodiments of theinvention are possible utilizing, alone or in combination, one or moreof the features set forth above or described in detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a scale model of a prototype carcass cabinet,according to embodiments of the present invention;

FIG. 2 is a side view of a scale model of a prototype carcass cabinet,according to embodiments of the present invention;

FIG. 3 is a top view of a scale model of a prototype carcass cabinet,according to embodiments of the present invention;

FIG. 4 is a bottom view of a scale model of a prototype carcass cabinet,according to embodiments of the present invention;

FIG. 5 is a top view of a scale model of a prototype carcass cabinetclosure, according to embodiments of the present invention;

FIG. 6 is a perspective view of an exploded scale model of a prototypecarcass cabinet, according to embodiments of the present invention;

FIG. 7 is an illustration of a prior art apparatus for antimicrobialtreatment of meat products;

FIG. 8 is a side view of a carcass cabinet system, according toembodiments of the present invention; and

FIG. 9 is an overhead view of a carcass cabinet system, according toembodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as is commonly understood by one of ordinary skillin the art. All patents, applications, published applications, and otherpublications to which reference is made herein are incorporated byreference in their entirety. In the event that there is a plurality ofdefinitions for a term herein, the definition provided in the BriefSummary of the Invention prevails unless otherwise stated.

As used herein, the term “animal carcass” is used to mean both a wholeanimal carcass, and any portion of a carcass of an animal which has beencut, split, or otherwise separated from a remainder of the carcass.

Referring now to FIGS. 1 through 6, an apparatus for applying anantimicrobial agent to whole or split animal carcasses includes a closedor essentially closed chamber for limiting the escape of antimicrobialagent to the environment during antimicrobial treatment of the carcass.A series of carcass cabinet panels move in line with the passing animalcarcass and form an enclosure around the carcass by means of panelsclosing ahead of and behind the carcass. The center carcass cabinetpanel remains parallel to the carcass on either side of the movingcarcass. The leading and trailing carcass cabinet panels move the paneledged furthest from the center panel toward a position directly belowthe carcass main chain. Each carcass cabinet center panel, inconjunction with the attached forward and trailing panels, forms a180-degree enclosure around the target carcass. Two separate 180-degreeenclosures come together to form a single 360-degree enclosure thatsurrounds the carcass by carcass cabinet walls. The carcass cabinetcenter panels on either side of the carcass are bent at a 90-degreeangle toward the center chain at the top and bottom of the cabinetpanel. The carcass cabinet panels that lead and trail the center panelare also bent at a 90-degree angle toward the main chain. The cabinetpanel ends (including the upper and lower leading, center, and trailingpanels) form a closed end on the top and bottom of the 360-degreecarcass enclosure. The carcass hook attached to the main chain is theonly point at which the enclosure is not fully separated from theexterior environment. The hole in the top of the 360-degree enclosure,by means of some expansive or rubber material, is sealed to preventantimicrobial escape from around the carcass hook.

When the enclosure is fully sealed, nozzles installed toward the top ofboth center panels commence the antimicrobial application process. Theprocess fully covers the carcass by means of electrostatic nozzles thatcreate an attraction between the aerosolized antimicrobial agent and thecontained carcass.

Air-assisted electrostatic sprayers produce electrically charged spraydroplets of the antimicrobial agent, which are carried to the targetcarcass in an air stream. Electrical charges on the surface of the sprayparticles cause the particles to be attracted to the target carcass. Thecharged spray particles follow electric field lines around the targetcarcass, wrapping around the carcass and coating it on all sides.

The enclosed carcass chamber is then evacuated by means of a portlocated toward the lower end of the center cabinet panels. A source ofrelief air is drawn into the full enclosure through an upper port,allowing the chamber air, including the aerosolized antimicrobial, to beevacuated through the lower evacuation port.

When completely evacuated, the carcass cabinet begins the chamberseparation process, starting with the leading edge of the forward panel.The forward panels falls back to be in line with the center panel, asdoes the panel trailing the center panel. The three connected panels arethen parallel to the moving carcass. The panels then move along a routedefined by drive chains located at upper and lower contact points of thecarcass cabinet panel. The cabinet panel chains and connected panelsmake a 180-degree turn away from the moving carcass, toward the processstarting point, and then make a second 180-degree turn, toward the nextmoving carcass. The process then repeats.

The retractable carcass cabinet temporarily creates an individualchamber around each carcass while moving at speeds typical of anindustrial processing chain. The closed or essentially closed chamberallows for the use of a wide range of intervention technologies andpractices while safeguarding worker welfare in the immediate vicinity.

Electrostatic application of antimicrobial agents results inaerosolization of the antimicrobial agents, with particle sizes betweenabout 20 and about 60 microns. These particles receive an electricalcharge from the spray nozzle, causing the particles to be attracted tothe surface of the target carcass by a force about 75 times strongerthan gravity. The small particles adhere to the carcass in a highlyuniform, thin layer, resulting in more complete coverage. The enclosurealso allows for increased concentrations of antimicrobial agents orother intervention compounds, as the chamber prevents escape to thesurrounding work area.

The retractable carcass cabinet enables continuous processing of largenumbers of animal carcasses, surrounding each carcass as it passes(while being driven by a carcass hook/chain), and then retracts awayafter treatment of each carcass.

Prior art apparatuses for antimicrobial treatment of meat productsgenerally prevent charged particulate from escaping from an enclosure bymeans of physical barriers, typically in the form of revolving doors orevacuation of air, as illustrated in the two highlighted portions ofFIG. 7. In addition to necessitating additional moving parts, which areprone to wear and eventual failure, prior art apparatuses tend to givean operator little to no control over the direction and spray pattern ofcharged particulate.

Referring now to FIGS. 8 and 9, in contrast to the prior art, carcasscabinet systems of the present invention do not rely solely on physicalbarriers to prevent charged particulate from escaping. As illustrated inFIGS. 8 and 9, in carcass cabinet systems 10 of the present invention,electrostatic nozzles 11 are fixed on carcass cabinet walls 12. Inembodiments, the carcass cabinet walls 12 may be made of stainlesssteel. Electrostatic nozzles 11 aerosolize a liquid antimicrobial agentand impart a positive charge to the aerosolized antimicrobial particles.In embodiments, the aerosolized antimicrobial particles may have anaverage diameter of between about 20 microns and about 60 microns. As aresult of their positive charge, the aerosolized antimicrobial particlesare attracted to the surfaces of carcasses 13, which are driven, by acarcass chain 14, through an interior space defined by carcass cabinetwalls 12. In embodiments, the attractive and/or adhesive force betweenthe surfaces of carcasses 14 and the aerosolized antimicrobial particlesmay be about 75 times the force of gravity. In the embodimentillustrated in FIG. 9, carcass cabinet walls 12 may define an interiorspace sufficient to accommodate multiple carcasses 13 at the same time.The positive charge of the aerosolized antimicrobial particles alsoserves to distribute the antimicrobial agent evenly over the surfaces ofcarcasses 13.

Although the use of electrostatic nozzles to impart a positive charge onaerosolized antimicrobial particles is effective to sterilize thesurfaces of carcasses 13, the aerosolized particles may, withoutintervention, have a tendency to drift outside the carcass cabinet walls12 and adhere to unintended surfaces, including workers in the nearvicinity of the carcass cabinet system 10. In particular, particles areliable to escape through the points at which carcasses 13 enter and exitthe cabinet, as well as through unsealed gaps at the top of the interiorspace surrounding the carcass chain 14. This problem of unintended driftis solved by ensuring that the positively charged antimicrobialparticles pass through a negatively charged magnetic field. Asillustrated in FIG. 9, negatively charged electromagnets 15 a,b areprovided at various points in the carcass cabinet walls 12. Theelectromagnets 15 attract the positively charged antimicrobialparticles, ensuring that the particles do not escape from the carcasscabinet walls 12. In embodiments, electromagnets 15 may be sideelectromagnets 15 a, i.e. disposed on an interior surface of verticalcarcass cabinet walls 12, or they may be overhead electromagnets 15 b,i.e. disposed on an interior surface of a ceiling or roof of carcasscabinet walls 12. No matter their placement, however, electromagnets 15are oriented to impart a negative magnetic charge into the interiorspace defined by carcass cabinet walls 12. As a result of theirattraction to electromagnets 15, the positively charged antimicrobialparticles will not drift toward gaps or holes by which they may escapeinto a surrounding environment. As antimicrobial particles are drawntoward electromagnets 15, they are captured and removed from theinterior space by air/particulate evacuation columns 16.

The invention illustratively disclosed herein suitably may be practicedin the absence of any element which is not specifically disclosedherein. It is apparent to those skilled in the art, however, that manychanges, variations, modifications, other uses, and applications of theinvention are possible, and also changes, variations, modifications,other uses, and applications which do not depart from the spirit andscope of the invention are deemed to be covered by the invention, whichis limited only by the claims which follow. By way of non-limitingexample, though the foregoing description of the invention has relatedto animal carcasses, systems and methods according to the invention maysterilize the surfaces of fruits and vegetables without departing fromthe spirit and scope of the invention. Likewise, by way of furthernon-limiting example, the negatively charged electromagnets as describedmay be replaced by static or rare-earth magnets without departing fromthe spirit and scope of the invention. Similarly, by way of additionalnon-limiting example, though the foregoing description of the inventionhas related to a positively charged aerosol spray and a negativelycharged electromagnet, those of ordinary skill in the art would be ableto understand and implement the converse, i.e. negatively chargedaerosol spray and positively charged electromagnets, without departingfrom the spirit and scope of the invention.

The foregoing discussion of the invention has been presented forpurposes of illustration and description. The foregoing is not intendedto limit the invention to the form or forms disclosed herein. In theforegoing Detailed Description of the Invention, for example, variousfeatures of the invention are grouped together in one or moreembodiments for the purpose of streamlining the disclosure. The featuresof the embodiments of the invention may be combined in alternateembodiments other than those discussed above. This method of disclosureis not to be interpreted as reflecting an intention that the claimedinvention requires more features than are expressly recited in eachclaim. Rather, as the following claims reflect, inventive aspects lie inless than all features of a single foregoing disclosed embodiment. Thus,the following claims are hereby incorporated into this DetailedDescription of the Invention, with each claim standing on its own as aseparate preferred embodiment of the invention.

Moreover, though the description of the invention has includeddescription of one or more embodiments and certain variations andmodifications, other variations, combinations, and modifications arewithin the scope of the invention, e.g. as may be within the skill andknowledge of those in the art, after understanding the presentdisclosure. It is intended to obtain rights which include alternativeembodiments to the extent permitted, including alternate,interchangeable, and/or equivalent structures, functions, ranges, orsteps to those claimed, whether or not such alternate, interchangeable,and/or equivalent structures, functions, ranges, or steps are disclosedherein, and without intending to publicly dedicate any patentablesubject matter.

1. A retractable carcass cabinet, comprising: a top enclosure,comprising a leading top panel, a center top panel, and a trailing toppanel; and a bottom enclosure, comprising a leading bottom panel, acenter bottom panel, and a trailing bottom panel, wherein the top andbottom enclosures are configured to move between a retracted positionand a sealing position, and wherein, when the top and bottom enclosuresare in a sealing position, the top and bottom enclosures together form asubstantially airtight closed chamber.
 2. The retractable carcasscabinet of claim 1, further comprising: an electrostatic nozzle,disposed on an underside of the center top panel and adapted to providean electrostatic spray of an antimicrobial agent into the substantiallyairtight closed chamber; an evacuation port, disposed on the bottomenclosure and adapted to evacuate the substantially airtight closedchamber; and a relief air port, disposed on the top enclosure andadapted to inject air into the substantially airtight closed chamber. 3.The retractable carcass cabinet of claim 1, wherein a carcass hook isdisposed through a sealed opening in the top enclosure and extends belowthe top enclosure.
 4. The retractable carcass cabinet of claim 3,wherein the carcass hook is attached to a carcass chain above the topenclosure.
 5. A system for antimicrobial treatment of at least oneanimal carcass, comprising: a plurality of carcass cabinet walls,defining an interior volume; a plurality of electrostatic nozzles,aerosolizing a liquid antimicrobial agent to form aerosolizedantimicrobial particles, imparting a positive charge to the aerosolizedantimicrobial particles, and spraying the aerosolized antimicrobialparticles into the interior volume; a carcass chain, carrying the atleast one animal carcass and driving the at least one animal carcassthrough the interior volume such that at least a first portion of theaerosolized antimicrobial particles adheres to a surface of the at leastone animal carcass to form a substantially uniform layer of theantimicrobial agent; a plurality of negatively charged electromagnets,each negatively charged electromagnet imparting a negative charge to anevacuation region within the interior volume to attract at least asecond portion of the aerosolized antimicrobial particles into theevacuation region; and a plurality of evacuation columns, eachevacuation column associated with at least one negatively chargedelectromagnet and evacuating substantially all of the aerosolizedantimicrobial particles within the evacuation region from the interiorvolume.
 6. The system of claim 5, wherein the at least one animalcarcass comprises a whole animal carcass.
 7. The system of claim 6,wherein the whole animal carcass is a whole bird carcass.
 8. The systemof claim 5, wherein the at least one animal carcass comprises a portionof a carcass of an animal that has been cut, split, or otherwiseseparated from a remainder of the carcass.
 9. The system of claim 8,wherein the animal is a bird.
 10. The system of claim 5, wherein thecarcass cabinet walls comprise stainless steel.
 11. The system of claim5, wherein the aerosolized antimicrobial particles have an averagediameter of between about 20 microns and about 60 microns.
 12. Thesystem of claim 5, wherein an attractive force between the surface ofthe at least one animal carcass and the layer of the antimicrobial agentis equal to about 75 times the force of gravity.
 13. A method forcontinuous antimicrobial treatment of animal carcasses, comprising: a)providing a plurality of carcass cabinet walls defining an interiorvolume; b) aerosolizing a liquid antimicrobial agent to form aerosolizedantimicrobial particles; c) imparting a positive charge to theaerosolized antimicrobial particles; d) spraying the aerosolizedantimicrobial particles into the interior volume; e) driving at leastone animal carcass through the interior volume such that at least afirst portion of the aerosolized antimicrobial particles adheres to asurface of the at least one animal carcass to form a substantiallyuniform layer of the antimicrobial agent; f) imparting a negative chargeto at least one evacuation region within the interior volume to attractat least a second portion of the aerosolized antimicrobial particlesinto the at least one evacuation region; and g) evacuating substantiallyall of the aerosolized antimicrobial particles within the evacuationregion from the interior volume.
 14. The method of claim 13, wherein theat least one animal carcass comprises a whole animal carcass.
 15. Themethod of claim 14, wherein the whole animal carcass comprises a wholebird carcass.
 16. The method of claim 13, wherein the at least oneanimal carcass comprises a portion of a carcass of an animal that hasbeen cut, split, or otherwise separated from a remainder of the carcass.17. The method of claim 16, wherein the animal is a bird.
 18. The methodof claim 13, wherein the carcass cabinet walls comprise stainless steel.19. The method of claim 13, wherein the aerosolized antimicrobialparticles have an average diameter of between about 20 microns and about60 microns.
 20. The method of claim 13, wherein an attractive forcebetween the surface of the at least one animal carcass and the layer ofthe antimicrobial agent is equal to about 75 times the force of gravity.